Camshafts, followers and valve gear (NA)

Head-off work. For the timing chain see NA timing chain. The torque and clearance figures are on Torque values.

Camshafts

NA (Z22SE) only.

Remove

1. Open the bonnet.
2. Disconnect the battery.
3. Open the engine cover.
4. Detach the engine cover. (6 bolts)
5. Release the fuel pressure.
6. Disconnect the fuel lines. (2 union nuts; 2 bolts; Reposition the fuel lines to one side.)
7. Detach the ignition module.
   • Release and detach the wiring harness connector.
   • 4 bolts
8. Remove the cylinder head cover. (Detach the engine breather hose.; 2 bolts, 1 nut; 1 bolt; 12 bolts)
9. Raise the lifting ramp.
10. Remove the lower engine splash shield. (13 bolts)
11. Align the crankshaft.
    • Rotate the crankshaft in the normal direction of rotation to
12. Lower the lifting ramp.
13. Remove the guide rail. (2 bolts)
14. Note: If there is no marking on the camshaft timing chain tensioner, then it should be replaced with a new camshaft timing chain tensioner (part number 24 448 509) including a new camshaft timing chain tensioner rail (part number 24 449 448).
15. Remove the camshaft timing chain tensioner.
16. Attach KM-6148. Note: In this position the cams of cylinder no. 4 point upwards.
    • Attach KM-6148 with the enclosed
    • Slide the positioning bolts into the designated bores
17. Detach the exhaust camshaft sprocket. (Hold the exhaust camshaft by the hexagon.; Pull back the positioning bolt to release.)
18. Detach the intake camshaft sprocket. (Hold the intake camshaft by the hexagon.)
19. Detach the camshaft connecting flange cover. (2 bolts)
20. Remove the intake camshaft.
21. Take out the roller cam followers.
22. Remove the exhaust camshaft.
    • Visually inspect the camshaft and the camshaft bearings for (Working in a spiral pattern from the outside towards the middle, release the bolts on the camshaft bearing caps (I to V) 1/2 to 1 turn at a time. Note: The camshaft must be released evenly from the bearings.; Take out the camshaft.; Visually inspect the camshaft and the camshaft bearings for wear. Note: The cylinder head should be replaced if the camshaft bearings are defective.)

Install

23. Install the exhaust camshaft. (Coat the sliding surfaces with engine oil.)
24. Insert the roller cam followers. (Coat the sliding surfaces with engine oil.)
25. Install the intake camshaft.
    • Clean the sealing surfaces of camshaft bearing cap no.11.
    • Coat the sliding surfaces with engine oil.
26. Install the camshaft bearing caps.
    • Coat the sealing surfaces of camshaft bearing cap no. 11 with
27. Attach the camshaft connecting flange cover. (Use a new gasket.; Tightening torque 23 Nm)
28. Attach the intake camshaft sprocket.
    • Use a new bolt.
    • Tightening torque 85 Nm + 30° + (Tightening torque 85 Nm + 30° + 15°)
29. Attach the exhaust camshaft sprocket.
    • Rotate the exhaust camshaft by the hexagon until the exhaust
    • Use a new bolt.
    • Tightening torque 85 Nm + 30° + (Pull back the positioning bolt to secure the camshaft sprocket.; Tightening torque 85 Nm + 30° + 15°)
30. Install the camshaft timing chain tensioner.
    • Insert the piston into the housing. (Clamp the piston at the square into a vice.; Turn clockwise to lock the internal piston in the last latch position.)
    • Use new oil seals.
    • Tightening torque 75 Nm
31. Release the camshaft timing chain tensioner by pressing on the tensioner rail or the camshaft timing chain (using a blunt tool – e.g. a rounded assembly lever).
32. Recut the thread. (2 off)
33. Install the guide rail. (Tightening torque 8 Nm)
34. Raise the lifting ramp.
35. Rotate the crankshaft 720°.
    • Rotate the crankshaft in the normal direction of rotation to
36. Note: In this position the cams of cylinder no. 4 point upwards, and it must be possible to insert blocking tool KM-6148.
37. Install the lower engine splash shield
38. Lower the lifting ramp.
39. Detach KM-6148.
40. Attach the cylinder head cover
    • Clean the sealing surfaces.
    • Tightening torque 9 Nm
    • Tightening torque 9 Nm
    • 2 bolts, 1 nut
    • Attach the engine breather hose.
    • Tightening torque 8 Nm
41. Attach the ignition module.
    • Tightening torque 9 Nm
    • Attach and secure the wiring harness connector.
42. Attach the exhaust camshaft sprocket.
    • Rotate the exhaust camshaft by the hexagon until the exhaust
    • Use a new bolt.
    • Tightening torque 85 Nm + 30° + (Tightening torque 85 Nm + 30° + 15°)
43. Connect the fuel lines. (Tightening torque 10 Nm; Tightening torque 9 Nm)
44. Install the rear engine cover. (Check the alignment.; 6 bolts, tightening torque 14 Nm)
45. Close the rear engine cover.
46. Connect the battery.
47. Close the bonnet.
48. Reprogram the volatile memories.

Camshaft sprockets

NA (Z22SE) only.

Remove

1. Open the bonnet.
2. Disconnect the battery.
3. Open the engine cover.
4. Detach the engine cover. (6 bolts)
5. Release the fuel pressure. Note: Fuel may escape – observe the safety regulations and relevant national legislation.
   • Collect any escaping fuel in a suitable container.
6. Disconnect the fuel lines. (2 union nuts; 2 bolts; Reposition the fuel lines to one side.)
7. Detach the ignition module.
   • Release and detach the wiring harness connector.
   • 4 bolts
8. Remove the cylinder head cover. (Detach the engine breather hose.; 2 bolts, 1 nut; 1 bolt; 12 bolts)
9. Raise the lifting ramp.
10. Remove the lower engine splash shield. (13 bolts)
11. Align the crankshaft.
    • Rotate the crankshaft in the normal direction of rotation to
12. Lower the lifting ramp.
13. Remove the guide rail. (2 bolts)
14. Note: If there is no marking on the camshaft timing chain tensioner, then it should be replaced with a new camshaft timing chain tensioner (part number 24 448 509) including a new camshaft timing chain tensioner rail (part number 24 449 448).
15. Remove the camshaft timing chain tensioner.
16. Remove the exhaust camshaft sprocket.
    • Mark the chain link next to the EXH marking on the
    • Hold the exhaust camshaft by the hexagon.
    • Take out the exhaust camshaft sprocket.
17. Remove the intake camshaft sprocket.
    • Mark the chain link next to the INT marking on the
    • Hold the intake camshaft by the hexagon.
    • Pull back the positioning bolt.
    • Take out the intake camshaft sprocket.
    • Slide in the positioning bolt.
    • Hang the camshaft timing chain over the positioning bolt.

Install

18. Install the intake camshaft sprocket.
    • Marked chain link to INT marking on the intake camshaft (Pull back the positioning bolt.; Marked chain link to INT marking on the intake camshaft sprocket)
    • Slide the positioning bolts into the designated bores in the
    • Tightening torque 85 Nm + 30° + (Hold the intake camshaft by the hexagon.; Tightening torque 85 Nm + 30° + 15°)
19. Install the exhaust camshaft sprocket.
    • Marked chain link to EXH marking on the exhaust (Pull back the positioning bolt.; Marked chain link to EXH marking on the exhaust camshaft sprocket)
    • Slide the positioning bolt into the designated bore in the
    • Tightening torque 85 Nm + 30° + (Hold the exhaust camshaft by the hexagon.; Tightening torque 85 Nm + 30° + 15°)
20. Install the camshaft timing chain tensioner.
    • Insert the piston into the housing. (Clamp the piston at the square into a vice.; Turn clockwise to lock the internal piston in the last latch position.)
    • Use new oil seals.
    • Tightening torque 75 Nm
21. Release the camshaft timing chain tensioner by pressing on the tensioner rail or the camshaft timing chain (using a blunt tool – e.g. a rounded assembly lever).
22. Recut the thread. (2 off)
23. Install the guide rail. (Tightening torque 8 Nm)
24. Raise the lifting ramp.
25. Rotate the crankshaft 720°.
    • Rotate the crankshaft in the normal direction of rotation to
26. Attach the lower engine splash shield. (13 bolts)
27. Note: In this position the cams of cylinder no. 4 point upwards, and it must be possible to insert blocking tool KM-6148.
28. Lower the lifting ramp.
29. Detach KM-6148.
30. Attach the cylinder head cover
    • Clean the sealing surfaces.
    • Tightening torque 9 Nm
    • Tightening torque 9 Nm
    • 2 bolts, 1 nut
    • Attach the engine breather hose.
    • Tightening torque 8 Nm
31. Attach the ignition module.
    • Tightening torque 9 Nm
    • Attach and secure the wiring harness connector.
32. Connect the fuel lines. (Tightening torque 10 Nm; Tightening torque 9 Nm)
33. Install the rear engine cover. (Check the alignment.; 6 bolts, tightening torque 14 Nm)
34. Close the rear engine cover.
35. Connect the battery.
36. Close the bonnet.
37. Reprogram the volatile memories.

Camshaft followers

NA (Z22SE) only.

Remove

1. Open the bonnet.
2. Disconnect the battery.
3. Open the engine cover.
4. Detach the engine cover. (6 bolts)
5. Release the fuel pressure.
6. Disconnect the fuel lines. (2 union nuts; 2 bolts; Reposition the fuel lines to one side.)
7. Detach the ignition module.
   • Release and detach the wiring harness connector.
   • 4 bolts
8. Remove the cylinder head cover.
   • Detach the engine breather hose.
   • Detach the engine lifting eyes.
   • 2 bolts, 1 nut
   • 1 bolt
   • 12 bolts
9. Raise the lifting ramp.
10. Remove the lower engine splash shield. (13 bolts)
11. Align the crankshaft.
    • Rotate the crankshaft in the normal direction of rotation to
12. Lower the lifting ramp.
13. Remove the guide rail. (2 bolts)
14. Note: If there is no marking on the camshaft timing chain tensioner, then it should be replaced with a new camshaft timing chain tensioner (part number 24 448 509) including a new camshaft timing chain tensioner rail (part number 24 449 448).
15. Remove the camshaft timing chain tensioner.
16. Attach KM-6148. Note: In this position the cams of cylinder no. 4 point upwards.
    • Attach KM-6148 with the enclosed
    • Slide the positioning bolts into the designated bores
17. Detach the exhaust camshaft sprocket. (Hold the exhaust camshaft by the hexagon.; Slide back the positioning bolt to release.)
18. Detach the intake camshaft sprocket. (Hold the intake camshaft by the hexagon.)
19. Detach the camshaft connecting flange cover. (2 bolts)
20. Remove the intake camshaft.
    • Visually inspect the camshaft and the camshaft bearings for (Working in a spiral pattern from the outside towards the middle, release the bolts on the camshaft bearing caps (I to VI) 1/2 to 1 turn at a time. Note: The camshaft must be released evenly from the bearings.; Take out the camshaft.; Visually inspect the camshaft and the camshaft bearings for wear. Note: The cylinder head should be replaced if the camshaft bearings are defective.)
21. Take out the roller cam followers.
22. Remove the exhaust camshaft.
    • Visually inspect the camshaft and the camshaft bearings for (Working in a spiral pattern from the outside towards the middle, release the bolts on the camshaft bearing caps (I to V) 1/2 to 1 turn at a time. Note: The camshaft must be released evenly from the bearings.; Take out the camshaft.; Visually inspect the camshaft and the camshaft bearings for wear. Note: The cylinder head should be replaced if the camshaft bearings are defective.)
23. Take out the roller cam followers.
24. Insert the roller cam followers. (Coat the sliding surfaces with engine oil.)

Install

25. Install the exhaust camshaft. (Coat the sliding surfaces with engine oil.)
26. Note the correct allocation.
27. Insert the roller cam followers.
28. Install the intake camshaft.
    • Clean the sealing surfaces of camshaft bearing cap no. 11.
    • Coat the sliding surfaces with engine oil.
29. Install the camshaft bearing caps.
    • Coat the sealing surfaces of camshaft bearing cap no. 11 with
30. Working in a spiral pattern from the middle towards the outside, tighten the bolts on the camshaft bearing caps (I to VI) in stages. (Tightening torque (M6) 9 Nm,)
31. Attach the camshaft connecting flange cover. (Use a new gasket.; Tightening torque 23 Nm)
32. Attach the intake camshaft sprocket.
    • Use a new bolt.
    • Tightening torque 85 Nm + 30° + (Tightening torque 85 Nm + 30° + 15°)
33. Attach the exhaust camshaft sprocket.
    • Rotate the exhaust camshaft by the hexagon until the exhaust
    • Use a new bolt.
    • Tightening torque 85 Nm + 30° + (Tightening torque 85 Nm + 30° + 15°)
34. Install the camshaft timing chain tensioner.
    • Insert the piston into the housing. (Clamp the piston at the square into a vice.; Turn clockwise to lock the internal piston in the last latch position.)
    • Use new oil seals.
    • Tightening torque 75 Nm
35. Release the camshaft timing chain tensioner by pressing on the tensioner rail or the camshaft timing chain (using a blunt tool – e.g. a smooth–edged assembly lever).
36. Recut the thread. (2 off)
37. Install the guide rail. (Tightening torque 8 Nm)
38. Raise the lifting ramp.
39. Rotate the crankshaft 720°.
    • Rotate the crankshaft in the normal direction of rotation to
40. Note: In this position the cams of cylinder no. 4 point upwards, and it must be possible to insert blocking tool KM-6148.
41. Install the lower engine splash shield (13 bolts)
42. Lower the lifting ramp.
43. Detach KM-6148.
44. Attach the cylinder head cover
    • Clean the sealing surfaces.
    • Tightening torque 9 Nm
    • Tightening torque 9 Nm
    • 2 bolts, 1 nut
    • Attach the engine breather hose.
    • Tightening torque 8 Nm
45. Attach the ignition module.
    • Tightening torque 9 Nm
    • Attach and secure the wiring harness connector.
46. Connect the fuel lines. (Tightening torque 10 Nm; Tightening torque 9 Nm)
47. Install the rear engine cover. (Check the alignment.; 6 bolts, tightening torque 14 Nm)
48. Close the rear engine cover.
49. Connect the battery.
50. Close the bonnet.
51. Reprogram the volatile memories.

Hydraulic tappets

NA (Z22SE) only.

Remove

1. Open the bonnet.
2. Disconnect the battery.
3. Open the engine cover.
4. Detach the engine cover. (6 bolts)
5. Release the fuel pressure.
6. Disconnect the fuel lines. (2 union nuts; 2 bolts; Reposition the fuel lines to one side.)
7. Detach the ignition module.
   • Release and detach the wiring harness connector.
   • 4 bolts
8. Remove the cylinder head cover.
   • Detach the engine breather hose.
   • 2 bolts, 1 nut
   • 1 bolt
   • 1 bolt
   • 12 bolts
9. Raise the lifting ramp.
10. Remove the lower engine splash shield. (13 bolts)
11. Align the crankshaft.
    • Rotate the crankshaft in the normal direction of rotation to
12. Lower the lifting ramp.
13. Remove the guide rail. (2 bolts)
14. Note: If there is no marking on the camshaft timing chain tensioner, then it should be replaced with a new camshaft timing chain tensioner (part number 24 448 509) including a new camshaft timing chain tensioner rail (part number 24 449 448).
15. Remove the camshaft timing chain tensioner.
16. Attach KM-6148. Note: In this position the cams of cylinder no. 4 point upwards.
    • Attach KM-6148 with the enclosed
    • Slide the positioning bolts into the designated bores
17. Detach the exhaust camshaft sprocket. (Hold the exhaust camshaft by the hexagon.; Slide back the positioning bolt to release.)
18. Detach the intake camshaft sprocket. (Hold the intake camshaft by the hexagon.)
19. Detach the camshaft connecting flange cover. (2 bolts)
20. Remove the intake camshaft.
    • Visually inspect the camshaft and the camshaft bearings for (Take out the camshaft.; Visually inspect the camshaft and the camshaft bearings for wear. Note: The cylinder head should be replaced if the camshaft bearings are defective.)
21. Take out the roller cam followers.
22. Take out the hydraulic tappets.
23. Remove the exhaust camshaft.
    • Visually inspect the camshaft and the camshaft bearings for (Take out the camshaft.; Visually inspect the camshaft and the camshaft bearings for wear. Note: The cylinder head should be replaced if the camshaft bearings are defective.)
24. Take out the roller cam followers.
25. Take out the hydraulic tappets.
26. Insert the hydraulic tappets.
27. Insert the roller cam followers.

Install

28. Insert the hydraulic tappets.
29. Insert the roller cam followers.
30. Install the intake camshaft.
    • Clean the sealing surfaces of camshaft bearing cap no. 11.
31. Install the camshaft bearing caps.
    • Coat the sealing surfaces of camshaft bearing cap no. 11 with
32. Working in a spiral pattern from the middle towards the outside, tighten the bolts on the camshaft bearing caps (I to VI) in stages. (Tightening torque (M6) 9 Nm,)
33. Attach the camshaft connecting flange cover. (Use a new gasket.; Tightening torque 23 Nm)
34. Attach the intake camshaft sprocket.
    • Use a new bolt.
    • Tightening torque 85 Nm + 30° + (Tightening torque 85 Nm + 30° + 15°)
35. Attach the exhaust camshaft sprocket.
    • Rotate the exhaust camshaft by the hexagon until the exhaust
    • Use a new bolt.
    • Tightening torque 85 Nm + 30° + (Pull back the positioning bolt to secure the camshaft sprocket.; Tightening torque 85 Nm + 30° + 15°)
36. Install the camshaft timing chain tensioner.
    • Insert the piston into the housing. (Clamp the piston at the square into a vice.; Turn clockwise to lock the internal piston in the last latch position.)
    • Use new oil seals.
    • Tightening torque 75 Nm
37. Release the camshaft timing chain tensioner by pressing on the tensioner rail or the camshaft timing chain (using a blunt tool – e.g. a rounded assembly lever).
38. Recut the thread. (2 off)
39. Install the guide rail. (Tightening torque 8 Nm)
40. Raise the lifting ramp.
41. Rotate the crankshaft 720°.
    • Rotate the crankshaft in the normal direction of rotation to
42. Note: In this position the cams of cylinder no. 4 point upwards, and it must be possible to insert blocking tool KM-6148.
43. Install the lower engine splash shield
44. Lower the lifting ramp.
45. Detach KM-6148.
46. Attach the cylinder head cover
    • Clean the sealing surfaces.
    • Tightening torque 9 Nm
    • Tightening torque 9 Nm
    • 1 nut, 1 bolt
    • Attach the engine breather hose.
    • Tightening torque 8 Nm
47. Attach the ignition module.
    • Tightening torque 9 Nm
    • Attach and secure the wiring harness connector.
48. Connect the fuel lines. (Tightening torque 10 Nm; Tightening torque 9 Nm)
49. Install the rear engine cover. (Check the alignment.; 6 bolts, tightening torque 14 Nm)
50. Close the rear engine cover.
51. Connect the battery.
52. Close the bonnet.
53. Reprogram the volatile memories.

Camshaft connection flange and bearing cap

NA (Z22SE) only.

Remove

1. Open the bonnet.
2. Disconnect the battery.
3. Open the engine cover.
4. Detach the engine cover. (6 bolts)
5. Release the fuel pressure.
6. Disconnect the fuel lines. (2 union nuts; 2 bolts; Reposition the fuel lines to one side.)
7. Detach the ignition module.
   • Release and detach the wiring harness connector.
   • 4 bolts
8. Remove the cylinder head cover. (Detach the engine breather hose.; 2 bolts, 1 nut; 1 bolt; 12 bolts)
9. Remove the camshaft connecting flange cover. (2 bolts)
10. Remove the camshaft connecting flange bearing cap.
    • 2 bolts
    • Visually inspect the camshaft bearings for wear.
11. Clean the sealing surfaces.

Install

12. Install the camshaft connecting flange bearing cap.
    • Coat the sliding surfaces with engine oil.
    • Coat the sealing surfaces (arrows) with silicone sealant (grey)
    • Tightening torque 22 Nm
13. Install the camshaft connecting flange cover. (Use a new gasket.; Tightening torque 23 Nm)
14. Attach the cylinder head cover
    • Clean the sealing surfaces.
    • Tightening torque 9 Nm
    • Tightening torque 9 Nm
    • 2 bolts, 1 nut
    • Attach the engine breather hose.
    • Tightening torque 8 Nm
15. Attach the ignition module.
    • Tightening torque 9 Nm
    • Attach and secure the wiring harness connector.
16. Connect the fuel lines. (Tightening torque 10 Nm; Tightening torque 9 Nm)
17. Install the rear engine cover. (Check the alignment.; 6 bolts, tightening torque 14 Nm)
18. Close the rear engine cover.
19. Connect the battery.
20. Close the bonnet.
21. Reprogram the volatile memories.

Camshaft connection flange cover

NA (Z22SE) only.

Procedure

1. Open the rear engine cover.
2. Remove the camshaft connecting flange cover. (2 bolts)
3. Install the camshaft connecting flange cover. (Use a new gasket.; Tightening torque 23 Nm)

Valves: removal

NA (Z22SE) only.

Install

1. Special service tools required:
2. Assembly tool set KM-6215, installation/removal set MKM-6086
3. Note: All attaching parts such as camshaft(s) and hydraulic valve lifters are removed.
4. Attach side mounts KM-6215-5 for lever KM-6215-4 to assembly device KM-6215-1. Attach lever KM-6215-4.
5. See operation "Cylinder head, disassemble", "Cylinder head, assemble".

Valve installation height check

NA (Z22SE) only.

Measure

1. Special service tools required:
2. Caliper Gauges, KM-419 (OHC I), KM-512 (OHC II), Measuring Bridge KM-301, Dial Gauge MKM-571-B
3. Preconditions:
4. Cylinder head sealing surface and valve heads are cleaned.
5. The installation height of the valves can be checked from both the underside and from the upper side of the cylinder head.
6. Valve indentation can be determined using Measuring Bridge KM-301 and Dial Gauge MKM-571-B.

Assemble

6. If the valve indentation cannot be determined, the extension provided should be inserted between dial gauge shaft and probe.
7. Measurement from Underside of Cylinder Head (Valve Indentation)
8. If the valve indentation cannot be determined, the extension provided should be inserted between dial gauge shaft and probe.

Clean

9. Position Measuring Bridge KM-301 on cleaned sealing surface, insert Dial Gauge MKM-571-B under pretension, fasten and adjust dial to Zero.

Inspect

11. Position Dial Gauge MKM-571-B with Measuring Bridge KM-301 at valve head and measure indentation of valve.
12. The specified valve indentation and the dimensions can be found in the "Technical Data".
13. The installation height of the valves should be measured from the upper side of the cylinder head using the depth gauge of a caliper gauge. The measurement is taken from the valve shaft end to the cylinder head.
14. The specified valve projection and the dimensions can be found in the "Technical Data".
15. Measurements are made using Distance Gauge KM-512.

Install

16. If dimension is exceeded, insert new valve and check valve stem projection again. If the valve stem projection is too great despite replacement of the valve, the cylinder head must be replaced.
17. The specified valve projection and the dimensions can be found in the "Technical Data".

Cylinder head: flatness check

NA (Z22SE) only.

Procedure

1. Clean the sealing surfaces. (Remove any gasket residue.)
2. Check for plane surface.
   • Use a straightedge, feeler gauges (Use a straightedge, feeler gauges Note: Height of the cylinder head (sealing surface to sealing surface): Dimension – 129 mm)